Container and container blank usable with a liquid impermeable bag

ABSTRACT

In accordance with aspects of the present invention, a single piece blank for forming a container configured for use with a liquid impermeable bag having a valve assembly is provided. The blank includes a bottom panel, opposed side panels and a top panel, opposite the bottom panel. Bottom end panels are hingedly attached to the bottom panel at opposite ends of the bottom panel. Formed in one of the bottom end panels is a hinge panel. Also formed in the same bottom end panel is a substantially circular, removable panel. The substantially circular removable panel is generally positioned between the hinge panel and the bottom panel. Further, each side panel includes either a primary end panel or a secondary end panel, wherein the primary end panel is larger than the secondary end panel.

FIELD OF THE INVENTION

This invention relates generally to containers and specifically to containers configured for use with internal bags for liquid products.

BACKGROUND OF THE INVENTION

Cartons or containers formed from folded corrugated paperboard or similar flat sheet stock material are often stacked on one another during shipping and storage of products. Corrugated containers with internal liquid impermeable bags are becoming a popular method of storing, shipping, and dispensing liquid and other viscous products as these types of containers generally cost less and are more environmentally friendly than other container types. However, many of the current corrugated containers designed to be used with internal bags are complex in their manufacture, difficult to erect, or overly complex with regards to accessing or controlling the dispensing of product from the bag.

SUMMARY OF THE INVENTION

In accordance with aspects of the present invention, a single piece blank for forming a container configured for use with a liquid impermeable bag having a valve assembly is provided. The blank includes a bottom panel, opposed side panels and a top panel, opposite the bottom panel. Bottom end panels are hingedly attached to the bottom panel at opposite ends of the bottom panel. Formed in one of the bottom end panels is a hinge panel. Also formed in the same bottom end panel is a substantially circular, removable panel. The substantially circular removable panel is generally positioned between the hinge panel and the bottom panel. Further, each side panel includes either a primary end panel or a secondary end panel, wherein the primary end panel is larger than the secondary end panel.

In accordance with another aspect of the present invention, a container configured for use with a liquid impermeable bag having a valve assembly is provided. The container includes a bottom panel, opposed side panels and a top panel. A manufacture's flap holds the bottom panel, side panels and top panel in position relative to one another. The container also includes a variety of end panels generally configured to close the ends of the container when formed. One of the end flaps hingedly attached to the bottom panel includes a hinge panel and a substantially circular removable panel. The hinge panel and the removable panel work in concert to hold the valve assembly in place while the container is used as intended. The side panels include different sized primary end panel and secondary end panels adjacent the bottom end panels to close the container.

BRIEF DESCRIPTION OF THE DRAWINGS

The preferred and alternative embodiments of the present invention are described in detail below with reference to the following drawings.

FIG. 1 is a plan view of a container blank formed in accordance with the present invention;

FIG. 2 is a perspective view of a partially erected container formed from the blank of FIG. 1;

FIG. 3 is another perspective view of a partially erected container formed from the blank of FIG. 1;

FIG. 4 is yet another perspective view of a partially erected container formed from the blank of FIG. 1; and,

FIG. 5 is a perspective view of a container made from the blank of FIG. 1.

DETAILED DESCRIPTION OF THE INVENTION

The present invention includes a single sheet of foldable material cut and scored to form a blank formable into a container. By way of overview and with reference to FIGS. 1-5, an embodiment of the present invention includes a single piece blank 20 arranged to form a container 46 generally configured to store and dispense material from a liquid impermeable bag with valve assembly. Specific details of the blank 20 and container 46 are described with more particularity below.

The present invention will now be described with reference to the accompanying FIGS. 1-5 where like numerals correspond to like elements. In all FIGURES, cut lines are shown as solid lines, score lines or lines of weakness are shown as broken lines. The present invention is directed to a tray-type container that utilizes a corner assembly to create a modular stackable container. The container includes an arrangement of panels, which are adapted to provide suitable container stability while providing simple and reliable control over product (not shown) dispensing.

For the purpose of further description herein, the downward direction is defined as the direction perpendicular to bottom panel 22 that corresponds to the outer surface of the bottom panel when the container has been erected, and the upward direction is defined as the direction perpendicular to the bottom panel that corresponds to the inner surface of the bottom panel when the container has been erected.

The blank 20 and resulting container 46 is typically made from any suitable material used in the shipping, storing or displaying of goods. Suitable, non limiting examples of such materials include paperboard, containerboard, cardboard, pasteboard, fiberboard, corrugated containerboard, corrugated paperboard, single wall corrugated containerboard, multi-wall corrugated containerboard or a combination thereof. As best shown in FIG. 1, blank 20 is stamped out of any of these suitable materials and assembled in a manner as depicted in FIGS. 1-5.

With continued reference to FIG. 1, the blank 20 includes a bottom panel 24 of generally rectangular shape having multiple edges. It will be appreciated, however, that the bottom panel 24 may also be of other geometries, such as, without limitation, square. Unless otherwise apparent, the term “edges” refers generally to a zone or line of weakness along which a part can be folded, such as a score line, or a cut line. Side wall panels 22 are hingedly connected to opposite side edges of the bottom panel 22 along fold lines 27 and 29 respectively. The bottom panel further includes bottom end panels 32, which are hingedly connected to the remaining two opposite edges of the bottom panel 22 along fold lines 25. A top panel 26 is hingedly attached to one of the side panels, opposite the bottom panel, along a fold line 33. On opposed ends of the top panel 26 are top end panels 36, which are hingedly attached to the top panel 26 along hinge lines 35.

Disposed within one of the bottom end panels 32 is structure to allow passage of the valve mechanism 46 of a liquid impermeable bag 48 (discussed in more detail below). Specifically, the structure includes a hinge panel 42 that is hingedly connected to the bottom end panel 32 along hinge line 17. The hinge panel 42 is separable from the bottom panel along lines of separation 19. Additionally, the structure includes a substantially circular removable panel 44. The removable panel 44 is separable from the bottom panel 32 along line of separation 15.

Disposed on opposite ends of one of the side panels 22 are primary end panels 30. Disposed on opposite end of the other side panel 22 are secondary end panels 30. The primary end panels 30 are larger that the secondary end panels 34. As such, when the container 46 is erected, the primary end panels 30 extend greater than 50% across the end of the container, in the fold direction. Conversely, the secondary end panels 34 extend less than 50% across the end of the container, in the fold direction, when the container 46 is erected. This is best seen in FIG. 4.

One primary end panel 30 includes a primary end panel cutout 38. The primary end panel cut out 38 is generally configured to substantially align with a section of the line of separation 19 that defines a portion of hinge panel 42 when the container 46 is erected. Further, one secondary end panel 34 includes a secondary end panel cutout 40. The secondary end panel cut out 40 is generally configured to also substantially align with another section of the lines of separation 19 that defines a further portion of hinge panel 42 when the container 46 is erected.

A bag 48 having a valve assembly 50 is also included. The bag 48 is generally configured to be disposed within the container 48. The valve assembly 50 is generally configured to be positioned within the container 46 until it is desired to release the contents of the bag 48. At such a time, removable panel 44 is removed, and hinge panel 42 is rotated about hinge line 17 to allow the valve assembly to be removed from the container 46 and engaged in the opening left by the removal of the removable panel 44. Then hinge panel 42 may be rotated back parallel with the bottom end panel 32 to help hold the valve assembly 46 in place. Suitable bags 48 and valve assemblies 50 are know in the art. As such, a detailed description of them is not contained herein. Additionally, for clarity purposes, the bag is only shown in one FIGURE. Further, it will be appreciated that the container 46 may also be used without a bag 48 without exceeding the scope of the present invention.

Referring now to FIGS. 2-5, one method of erecting the container 46 from the blank 20 will be described. In the ensuing description, erecting one side of the containers will be described. However, it will be appreciated that the other side of the container is formed in substantially similar steps. The first step begins with attaching the manufacture flap 28 to a portion of the top panel 26. The manufacture flap may be secured to the top panel 26 via any know method, such as, without limitation, mechanical fastening, tape, adhesive, or combinations thereof. The two distal edges of the container 46 are then biased toward one another to form the generally rectangular tube shown in FIG. 3. The primary end panels 30 and the secondary end panels 34 are then folded inwardly around their respective fold lines. Finally, the bottom panel 32 is folded inwardly and then the top panel 36 is folded inwardly to close the container 46. Similar to the fastening of the manufactures flap 28 discussed above, the various end panels may be attached to one another to seal the container 46.

In use, container 46 may be filled with product (not shown) and stacked with one or more other containers 46 on a pallet (not shown) or display shelf (not shown). In one possible application, a selected number of containers 46 filled with product (not shown) are stacked on pallet (not shown), and the pallet (not shown) may be moved from receiving directly to the display floor of the retailer (perhaps after removing an external common cover, strapping or wrap), where end-user purchasers have access to the pallet of containers.

While an embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. For example, the blank may also include other features specified by the customer, such as hand holds, vent holes, grease or moisture barriers and the like without exceeding the scope of the present invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow. 

1. A single sheet of foldable material cut and scored to define a container blank comprising: a bottom panel, said bottom panel having a side edge and an end edge; a pair of opposed side panels, each side panel being hingedly attached to the bottom panel along a respective side edge; a top panel hingedly attached to one of said side panel, opposite said bottom panel; a bottom end panel hingedly attached to said bottom panel along said end edge; a hinge panel formed entirely within the bottom end panel; and a substantially circular removable panel within bottom end panel.
 2. The blank of claim 1 wherein the container blank is formed from at least one of a paperboard, containerboard, cardboard, pasteboard, fiberboard, corrugated containerboard, corrugated paperboard, single wall corrugated containerboard, and multi-wall corrugated containerboard.
 3. The blank of claim 1 further comprising a liquid impermeable bag attached to an inside of the blank.
 4. The blank of claim 3 wherein said circular liquid impermeable bag further comprises a valve assembly.
 5. A container comprising: a bottom panel, said bottom panel having a side edge and an end edge; a pair of opposed side panels, each side panel being hingedly attached to the bottom panel along a respective side edge; a top panel hingedly attached to one of said side panel, opposite said bottom panel; a bottom end panel hingedly attached to said bottom panel along said end edge; a hinge panel formed entirely within the bottom end panel; and a substantially circular removable panel within bottom end panel.
 7. The container of claim 5 wherein the container is formed from at least one of a paperboard, containerboard, cardboard, pasteboard, fiberboard, corrugated containerboard, corrugated paperboard, single wall corrugated containerboard, and multi-wall corrugated containerboard.
 8. The container of claim 5 comprising a liquid impermeable bag attached to an inside of the container. 